Valve assembly, repair kit, and method for salvaging an aerosol container

ABSTRACT

A valve and/or repair kit assembly restores functionality to an aerosol container by being selectively and removably attachable the annular container rim adjacent the container outlet, which has been damaged or otherwise compromised. The valve assembly comprises a container-to-assembly interface fitting and a plunger assembly. The fitting interfaces the plunger assembly to the container, which plunger assembly comprises a sleeve, a nut, and a plunger structure. The sleeve comprises communicating cavities in which the nut and plunger structure are received. The plunger structure is coupled to the nut, each of which provide certain conduit. The fitting axially aligns the plunger assembly with the container outlet and matter-conducting conduit thus extends from the container outlet to the assembly outlet via the valve assembly. Certain methodology for discharging container contents is further supported by the valve assembly.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to a valve assembly for selective and removable attachment to an aerosol container. More particularly, the present invention relates to a valve assembly for selective and removable attachment to a standard aerosol container for salvaging container contents from said container, which container has been damaged or compromised at its container outlet.

2. Description of Prior Art

The prior art is fairly silent on replacement valve constructions for aerosol can dispensers and the like. Several of the more pertinent art disclosures, however distant or distinctive, are briefly described hereinafter. For example, U.S. Pat. No. 3,638,840 ('840 Patent), which issued to Ishida, discloses a Safety Valve for Aerosol Containers. The '840 Patent describes a safety valve for an aerosol container which permits the discharge of the residual propellant gases in a used container when the valve stem is broken off. The container is thereby rendered safe from explosion caused by heat and also cannot be refilled.

U.S. Pat. No. 4,911,336 ('336 Patent), which issued to Blake, discloses a Valve with Interchangeable Components. The '336 Patent describes a valve in which standardized, interchangeable components are used for converting the valve to use either in a manually operated pump or an aerosol valve. A poppet member is reciprocable in a valve chamber between a flexible valve housing and a main cylinder housing. By making minor modifications to the poppet member and cylinder housing the valve can be adapted or converted to use either in a manually operated pump dispenser or an aerosol dispenser.

Unique valve retaining means for attaching a valve to a container is also disclosed. In one form, snap detents secure together peripheral flanges of the valve housing and cylinder housing and also secure the housings to the container neck. In another form, interfitting structure on the flanges align the housings relative to one another, and a gasket is interposed between the flanges so as to seal the flanges relative to one another and relative to the container neck, with a retaining ferrule engaging and securing the flanges to the container neck.

U.S. Pat. No. 6,481,470 ('470 Patent), which issued to Rubenic, discloses an Aerosol Can and Contents Salvage Apparatus. The '470 Patent describes an apparatus for puncturing an aerosol can's valve, draining its contents through the puncture, and for drawing any remaining contents from the can should there be insufficient pressure in the can for it to be fully evacuated when punctured. When the valve is replaced, the can is reusable. The puncturing apparatus has a stationary compartmented piercing tube and a housing that is free to move up and down relative to the piercing tube.

The housing is spring-loaded to offer resistance to movement so that a seal is achieved between the housing and the can before the piercing tube makes contact with the can, and to return the housing to its rest position after each piercing cycle. An air cylinder is used to apply pressure to the bottom of the aerosol can so that it will move downward to engage the piercing tube and release its contents into a first compartment. A drawing cylinder contains a piston and uses vacuum means to draw contents from the aerosol can and mechanical mean to transfer such content from the apparatus through a discharge port.

The prior art thus perceives a need for a valve assembly that is selectively and removably attachable to an aerosol container at its container outlet so that users may discharge container contents from the aerosol container despite its having a damaged or otherwise compromised container outlet.

SUMMARY OF THE INVENTION

It is thus an object of the current invention to provide a low cost valve assembly designed to restore the functionality of an aerosol spray can by restoring its ability to dispense contents in the manner in which it was originally intended. The valve assembly according to the present invention is designed to be usable on aerosol spray cans either in which the valve stem is integral to the valve body and the stem is broken off or in which the valve stem is non-integral to the valve body but rather integral to the nozzle and the nozzle is lost. It is designed to fit all aerosol spray cans known to be currently used for paints, lubricates, etc. without need of modification of either the valve assembly or any known aerosol spray can design.

The valve assembly is designed to be reusable and to be compatible with most products dispensed with aerosol spray cans. This is generally accomplished by use of O-rings for sealing that can be readily changed and by use of structural materials common to most aerosol spray cans. It is designed to allow nozzles to be easily changed/interchanged. This allows the delivery spray pattern to be changed; e.g., stream, mist, etc. In addition, this allows replacement of clogged nozzles. Further, the valve assembly is designed to make assembly, cleaning and other maintenance most simple. Total disassembly requires no tools.

The valve assembly is designed to simplify the changing of seals if required for compatibility with a product dispensed from an aerosol spray can. It is designed to minimize the learning curve attendant to its use by way of operational simplicity. It is designed so as to make prerequisite preparation of an aerosol spray can for usage of the valve assembly in combination therewith unnecessary or minimal.

To achieve these and other readily apparent objectives, the present invention essentially provides a valve assembly for restoring functionality to an aerosol container as originally intended, which aerosol container has an annular container rim and a container outlet. The valve assembly according to the present invention comprises a container-to-assembly interface fitting and a plunger assembly.

The fitting comprises a rim-receiving slot and a through-hole. The slot has a rim-receiving mouth and is defined by a C-shaped flange opposed to a rim-covering lid. The through-hole extends orthogonally from the lid. The rim-receiving mouth has a mouth width greater in magnitude than the diameter of the container rim for receiving the container rim. The flange secures the fitting to the aerosol container via the container rim.

The plunger assembly comprises a sleeve, a nut, and a plunger. The sleeve comprises nut-receiving and plunger-receiving cavities, which cavities are in communication with one another. The nut is received in the nut-receiving cavity and comprises a plunger-coupling cavity and a conduit inlet communicatively engageable with the container outlet.

The plunger is received in the plunger-receiving and plunger-coupling cavities and comprises certain plunger conduit and an assembly outlet. The plunger is coupled to the nut thereby providing matter-conducting conduit from the conduit inlet to the assembly outlet. The sleeve is coupled to the through-hole for enabling matter to pass from the container outlet to the assembly outlet via the conduit inlet and plunger conduit.

The plunger assembly may further comprise certain spring means for biasing the plunger and nut to a non-activated position, which spring means enable the user to selectively discharge container contents. Further, the plunger assembly may further comprise certain sealing or gasket means for enhancing sealed and directed delivery of container contents from the container outlet to the conduit outlet.

The plunger or plunger structure may comprise a shaft and at least one interchangeable nozzle, the shaft and each interchangeable nozzle being coupled to one another for enabling the user to selectively interchange one or more interchangeable nozzles. The interface between the shaft and each interchangeable nozzle is preferably tapered for enhancing the seal intermediate the shaft and each interchangeable nozzle and for effecting a slip resistant interface.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features of my invention will become more evident from a consideration of the following brief description of patent drawings:

FIG. 1 is cross-sectional side view depiction of a first embodiment of the valve assembly according to the present invention having a non-integral nozzle and plunger shaft attached to a generic aerosol container at its upper container rim showing the valve assembly in a relaxed, non-activated state.

FIG. 2 is cross-sectional side view depiction of the first embodiment of the valve assembly otherwise depicted in FIG. 1 showing the valve assembly in an activated state.

FIG. 3 is cross-sectional side view depiction of a second embodiment of the valve assembly according to the present invention having an integral nozzle and plunger shaft element attached to a generic aerosol container at its upper container rim showing the valve assembly in a relaxed, non-activated state.

FIG. 4 is cross-sectional side view exploded depiction of the first embodiment of the valve assembly according to the present invention, showing from top to bottom, a nozzle element, a plunger shaft element, a spring element, a washer element, a plunger O-ring element, a threaded sleeve element, a plunger nut element, a sleeve O-ring element, and an interface fitting element.

FIG. 5 is an enlarged cross-sectional side view depiction of the nozzle element otherwise shown in FIG. 4.

FIG. 6 is an enlarged cross-sectional side view depiction of the plunger shaft element otherwise shown in FIG. 4.

FIG. 7 is an enlarged cross-sectional side view depiction of an alternative integral nozzle and shaft element otherwise depicted in FIG. 3.

FIG. 8 is an enlarged perspective view of an exemplary spring element according to the present invention.

FIG. 9 is an enlarged perspective view of an exemplary washer element according to the present invention.

FIG. 10 is an enlarged perspective view of an exemplary plunger type O-ring element according to the present invention.

FIG. 11 is an enlarged cross-sectional side view depiction of the threaded sleeve element otherwise depicted in FIG. 4.

FIG. 12 is an enlarged bottom perspective view of the threaded sleeve element according to the present invention showing an internal flat structure.

FIG. 13 is an enlarged top perspective view of a sectioned plunger nut element according to the present invention showing internal threads and a nut-to-container outlet interface or nut-based inlet.

FIG. 14 is an enlarged top perspective view of a sleeve-based O-ring element according to the present invention.

FIG. 15( a) is an enlarged bottom perspective view of a container-to-valve assembly interface fitting element according to the present invention showing a rim-receiving slot, defined, in part, by a C-shaped flange.

FIG. 15( b) is an enlarged cross-sectional side view depiction of the container-to-valve assembly interface fitting element as otherwise depicted in FIG. 4.

FIG. 16 is an enlarged fragmentary sectional depiction of the upper portion of a standard or exemplary aerosol container outfitted with the second embodiment of the valve assembly according to the present invention, which valve assembly is also shown in cross-section depicting a flow path of container contents from the container to the nozzle outlet.

FIG. 16( a) is a sectional depiction of a standard or exemplary aerosol container outfitted with the second embodiment of the valve assembly according to the present invention, which valve assembly is also shown in cross-section.

FIG. 17 is an enlarged fragmentary sectional depiction of the upper portion of a standard or exemplary aerosol container showing an integral valve stem and body (with nozzle removed therefrom).

FIG. 17( a) is a sectional depiction of a standard or exemplary aerosol container showing an integral valve stem and body (with nozzle removed therefrom).

FIG. 18 is an enlarged fragmentary sectional depiction of the upper portion of a standard or exemplary aerosol container showing an integral valve stem and body with nozzle attached thereto and depicting a flow path of container contents.

FIG. 18( a) is a sectional depiction of a standard or exemplary aerosol container showing an integral valve stem and body with nozzle attached thereto.

FIG. 19 is an enlarged fragmentary sectional depiction of the upper portion of a standard or exemplary aerosol container showing a valve stem non-integral to the valve body but rather integral to the nozzle.

FIG. 19( a) is a sectional depiction of a standard or exemplary aerosol container showing a valve stem non-integral to the valve body but rather integral to the nozzle.

FIG. 20 is an enlarged fragmentary sectional depiction of the upper portion of a standard or exemplary aerosol container depicting the integral valve stem and nozzle removed from the container.

FIG. 20( a) is a sectional depiction of a standard or exemplary aerosol container depicting the integral valve stem and nozzle removed from the container.

FIG. 21 is an enlarged fragmentary sectional depiction of the upper portion of a standard or exemplary aerosol container depicting a trimmed valve stem in which the valve stem and body are integral (with nozzle removed therefrom).

FIG. 21( a) is a sectional depiction of a standard or exemplary aerosol container depicting a trimmed valve stem in which the valve stem and body are integral (with nozzle removed therefrom).

FIG. 22 is an enlarged fragmentary sectional depiction of the upper portion of a standard or exemplary aerosol container depicting a valve stem which is integral with the valve body and in need of trimming (with the nozzle removed therefrom).

FIG. 22( a) is a sectional depiction of a standard or exemplary aerosol container depicting a valve stem which is integral with the valve body and in need of trimming (with the nozzle removed therefrom).

FIG. 23 is an enlarged fragmentary sectional depiction of the upper portion of a standard or exemplary aerosol container depicting a valve stem which is integral with the valve body and not in need of trimming (with the nozzle removed therefrom).

FIG. 23( a) is a sectional depiction of a standard or exemplary aerosol container depicting a valve stem which is integral with the valve body and not in need of trimming (with the nozzle removed therefrom).

FIG. 24 is an enlarged cross-sectional side view depiction of a container rim with an interface fitting attached thereto (with parts removed from said interface fitting) to show the diameter of the container rim relative to the width of the rim-receiving mouth width of the interface fitting.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

A typical aerosol can or container (as at 11) contains two substances. One substance is an inert gas used as a propellant 12. The second substance is a liquid product 13, such as a lubricant, to be delivered by way of the propellant 12. The inert gas or propellant 12 is at high pressure and essentially pushes on the product 13 such that the product 13 travels through the container conduit 14 and exits the container 11 via a container outlet 15 as generally depicted in FIG. 18 via a product flow path generally depicted by arrows 100.

The aerosol can or container 11 is valved such that the product 13 cannot escape the aerosol can or container 11 until the valve is opened, usually by pushing down on its nozzle. A container conduit 14 extends from the valve, which is at the top of the aerosol container 11, to the bottom of the aerosol container 1 1. If the valve is opened and the aerosol container 11 is upright, the product 13 is pushed by the pressurized inert gas 12 through the container conduit 14 and valve body 16 where it then typically exits the valve and aerosol container 11 through the valve's nozzle 17(a) or 17(b).

The valve assembly 20 and/or repair kit or assembly according to the present invention is designed to restore the functionality of an aerosol spray container 11 by restoring its ability to dispense container contents such as the product 13 in the manner in which it were originally intended. In this regard, it is to be noted that the valve assembly 20 is designed to be outfitted upon an aerosol spray can or container 11 either in which the valve stem is integral to the valve body 17(b) and the stem is broken off as generally and comparatively depicted in FIG. 18( a) and 23 or in which the valve stem is non-integral to the valve body but rather integral to the nozzle and the nozzle 17(a) is lost as generally and comparatively depicted in FIG. 19( a) and 20.

The valve assembly 20 according to the present invention is designed to make prerequisite preparation of an aerosol spray container 11 for aerosol can salvage valve assembly 20 usage unnecessary or minimal. A lost aerosol spray can valve's nozzle 17(a) requires no aerosol spray container 11 prerequisite preparation; however, if any protruding stem 18 is left when an aerosol spray can valve's nozzle 17(b) is broken off from an aerosol spray container's valve 16, the prerequisite preparation of the aerosol spray container 11 is minimal, and simply involves the removal with either a knife or scissors any protruding stem 18.

It should be further noted that the valve assembly 20 is designed to fit all aerosol spray cans or containers 11 known to be currently used for paints, lubricates, etc. without need of modification of either the valve assembly 20 or any known aerosol spray container 11 design. A generic aerosol container 11 of the type usable in combination with the valve assembly 20 is believed to be generally depicted in FIGS. 16-23( a).

The valve assembly 20 is designed to be reusable. In this regard, the valve assembly 20 is simply removable from a first aerosol spray can or container 11, whereafter the valve assembly 20 may be cleaned as required, and re-installed upon a second aerosol spray can or container 11. Further, the valve assembly 20 is designed to 20 be compatible with most products 13 as dispensed from aerosol spray cans or containers 11. This is preferably accomplished by use of gasket type O-rings for sealing that can be readily changed and by use of structural materials common to most aerosol spray cans or containers 11. A threaded sleeve O-ring 21 is generally depicted in FIGS. 4 and 14 and a plunger O-ring 22 is generally depicted in FIGS. 4 and 10.

The valve assembly 20 may be outfitted with a variety of different types of interchangeable nozzles, an example of which is generally depicted at 23 in FIGS. 4 and 5. The interchangeability of nozzles, as exemplified by nozzle 23, allows the user to change delivery of the spray pattern. In this regard, the spray pattern may be changed to effect a stream type pattern, a mist type pattern, etc. Further, the interchangeability of nozzles, as exemplified by nozzle 23, allows or enables the user to replace clogged nozzles.

It should be noted that an alternative, integral nozzle and shaft element 27 may be further provided, which otherwise combines a non-integral nozzle (as exemplified by nozzle 23) and plunger shaft (as exemplified by plunger shaft 29) into a single component as at integral nozzle and shaft element 27. The term plunger may thus be said to describe either the shaft 29 and nozzle 23 combination or the nozzle and shaft element 27.

In this last regard, it should be further noted that the valve assembly 20 is designed to make assembly, cleaning, and other maintenance thereof most simple. Total disassembly of the valve assembly 20 requires no tools. Notably, the flat or flat structure 24 on the plunger nut 25, which flat 24 interfaces with the threaded sleeve 26 allows the plunger nut 25 to be disengaged/engaged by simply holding the threaded sleeve 26 while twisting the plunger. The threaded sleeve 26 is disengaged/engaged from the aerosol can engagement interface fitting 28 by simply holding the aerosol can engagement interface fitting 28 while twisting the threaded sleeve 26.

The valve assembly 20 is further designed to simplify the changing of seals if required for compatibility with a product 13 dispensed from an aerosol spray container 11. The threaded sleeve O-ring 21 is exposed, and thus may be installed/removed manually with one's fingers. The plunger O-ring 22 is installed/removed by disengaging the plunger nut 25, pulling out the plunger assembly, sliding off from the plunger shaft 29 the old plunger O-ring 22, sliding a replacement plunger O-ring 22 onto the plunger shaft 29, reinserting the plunger assembly into the threaded sleeve 26, and lastly, engaging the plunger nut 25 by twisting the plunger. Notably, the valve assembly 20 is designed to preclude loss of the plunger nozzle(s) 23 or 27 from breakage due to abuse. This is accomplished by providing a close fit of appropriate length between the plunger nozzle(s) 23 or 27 and the threaded sleeve 26.

The valve assembly 20 is further designed to minimize the learning curve for usage through attachment simplicity. Attachment of the valve assembly 20 to a container 11 is simply achieved by slipping-on the aerosol can engagement fitting or interface fitting 28 followed by a twisting (e.g. clockwise or counter-clockwise depending on chirality of threads) of the threaded sleeve 26 to engage the threaded sleeve O-ring 21. In this last regard, the interface fitting 28 may be said to slot-receive the standardized container rim 10 after which the threaded sleeve 26 may be threadably received by the interface fitting 28.

When fully assembled upon an aerosol container 11, the valve assembly 20 is operated as any original aerosol spray can valve for which the aerosol can salvage valve assembly 20 can be used. In this regard, the nozzle or assembly outlet 30 of the valve assembly 20 may be pointed or aimed in the direction in which the dispensed product 13 is to be ejected, and then pushed down or depressed with one's finger for communicating the conduit inlet 31 (of the plunger nut 25) with the container outlet 15 such that the container contents or product 13 may travel through the conduit structures and exit the nozzle or assembly outlet 30.

The installation or outfitting of the aerosol can salvage valve assembly 20 onto an aerosol container 11 is believed to be fool proof by virtue of its design. The process of outfitting the target aerosol container 11 is accomplished by requiring only two operations which must be correctly performed in order to properly attach the aerosol can salvage valve assembly 20 to an aerosol spray can or container 11. Essentially, the aerosol can engagement interface fitting 28 will not fit if not engaged with the rounded protrusion 10 properly. Furthermore, the aerosol can engagement interface fitting 28 must be sufficiently engaged for the threaded sleeve 26 to fit over and around the aerosol spray can valve's external, centrally located protrusion 32. If this alignment is not correct, the aerosol can salvage valve assembly 20 will not function properly informing the user of improper attachment.

Accidental removal of the valve assembly 20 from the container 11 is further hindered or thwarted by the overall design of the assembly 20. In this regard, it is contemplated that the assembly design precludes separation of the aerosol can salvage valve assembly 20 from the aerosol spray container 11 due to abuse. This is accomplished by capturing/sandwiching the aerosol spray can's external valve body 16 between the aerosol can engagement interface fitting 28 and the threaded sleeve 26. In other words, the aerosol can salvage valve assembly 20 cannot slide off the container 11 since the threaded sleeve 26 fits over and around the aerosol spray can valve's external, centrally located protrusion 32.

In this last regard, it should be noted that the design of the rounded edge of the aerosol spray can valve's external, centrally located protrusion 32 is made useful or incorporated into the design of the assembly 20. In this regard, it is contemplated that as the threaded sleeve O-ring 21 is seated it is forced between the rounded edge of the aerosol spray can valve's external, centrally located protrusion 32 and the wall 33 of the threaded sleeve 26. This action centers the aerosol can salvage valve assembly 20 over the aerosol spray can's or container's exit valve or container outlet 15.

The efficacy of the plunger O-ring 22 seal is enhanced by ramping (as at 34) the plunger O-ring's seat towards the plunger shaft 29 and by the aerosol can salvage valve spring 35 further compressing the plunger O-ring 22 when either nozzle 23 or 37 of the aerosol can salvage valve assembly 20 is operated thereby increasing the pressures and the footprints at the plunger O-ring's 21 seat and the plunger shaft's 29 interface. Notably, the need for an O-ring installation/removal tool is eliminated. In this regard, the reader should take note that the threads 36 on the plunger shaft 29 (or integral nozzle and shaft element 27) engage the plunger O-ring 22 sufficiently to enable the plunger shaft 29 itself to function as a plunger O-ring installation/removal tool.

It is believed that the valve assembly 20 according to the present invention effectively eliminates the need for thread sealant. For assembly either the plunger shaft 29 or nozzle and shaft element 27 must be removed from the plunger nut 25 generally through the use of threads as at 36. In the case of an integral plunger nozzle and shaft element 27 and plunger shaft design as generally depicted in FIGS. 3 and 7, threads 36 are located upstream of the plunger O-ring 22, which structural location closes off the thread leakage path eliminating the need for thread sealant. In the case of the non-integral plunger nozzle 23 and plunger shaft 29 design as generally depicted in FIGS. 1, 2, and 4-6, a tapered interface as at 38(a) (shaft 29) and 38(b) (nozzle 23) between the plunger shaft 29 and the plunger nozzle 23 as opposed to threads is used eliminating the need for thread sealant.

In other words, an adequate seal between the non-integral plunger nozzle 23 and plunger shaft 29 is effected without the need for sealants. In this regard, it should be noted that the tapered interface between the non-integral plunger nozzle 23 and the plunger shaft 29 effects a seal. In addition, the tapered interface effects a slip resistant interface enabling one to twist the plunger shaft 29 for the adjustment of the plunger assembly's stroke. If leakage between the non-integral plunger nozzle 23 and plunger shaft 29 becomes a problem, then the integral plunger nozzle and shaft element 27 can be used.

The valve assembly 20 is further designed such that an exchange/replacement of the non-integral plunger nozzle 23 requires no tools. First the plunger assembly's stroke is adjusted to zero stroke. To achieve this end, the spring 35 may be compressed to its solid height by twisting the plunger assembly (clockwise) via the plunger nozzle 23. Then, the old plunger nozzle 23 is simply pulled off and a new plunger nozzle 23 is pushed onto the plunger shaft 29. When pulling, the plunger shaft 29 is constrained at the interface between the plunger nut 25 and the threaded sleeve 26. When pushing, the plunger shaft 29 is constrained by the fact that the spring 35 is compressed to its solid height providing essentially a rigid load path through the spring 35 and plunger O-ring 22 to the threaded sleeve 26.

Exchange/replacement of the plunger nozzle and shaft element 27 also requires no tools. The integral plunger nozzle-plunger shaft assembly is simply unscrewed from the plunger nut 25 by twisting the integral plunger nozzle-plunger shaft assembly (counter clockwise) until disengagement occurs. However, in this case, removal of the integral plunger nozzle-plunger shaft assembly may result in removal of the spring 35, plunger O-ring 22, and washer 39 all of which later need to be re-assembled onto the new integral plunger nozzle-plunger shaft assembly for insertion into the threaded sleeve 26.

The valve assembly 20 is designed to enable adjustment of the discharge rate of the aerosol spray can's contents or product 13 from off to its full discharge rate. This is accomplished by adjusting the stroke of the plunger assembly. As the plunger assembly's stroke is increased, the more the aerosol spray can's valve 16 is opened. The more the aerosol spray can's valve 16 is opened, the higher the discharge rate of the aerosol spray can's contents.

The depth of engagement of the plunger shaft 29 into the plunger nut 25 controls the stroke of the plunger assembly. The plunger assembly's stroke is dependent on the difference between the spring's 35 initial compressed height and its solid height (i.e. its fully compressed height). The spring's 35 initial compressed height is dependent on the depth of engagement of the plunger shaft 29 into the plunger nut 25. As the depth of engagement is increased, the spring's 35 initial compressed height decreases until its solid height is reached at which point the plunger assembly's stroke is zero because the difference between the spring's 35 initial compressed height and its solid height is zero.

The valve assembly 20 is further designed to inhibit unintentional change in the aerosol spray can's discharge rate adjustment. This is accomplished by the friction locking action of the plunger O-ring 22. When the aerosol can salvage valve assembly 20 is operated the pressures and the footprints at the plunger O-ring's 22 seat and the plunger shaft's 29 interface increase. This effects an increase in friction which operates to resist twisting of the plunger shaft 29 thereby inhibiting unintentional change in the aerosol spray can's discharge rate adjustment.

It will thus be seen that the present invention generally concerns a valve assembly 20 for restoring functionality to a standard aerosol container 11 either in which the valve stem is integral to the valve body and the stem is broken off or in which the valve stem is non-integral to the valve body but rather integral to the nozzle and the nozzle is lost. In either case, the aerosol container 11 is rendered inoperable unless re-outfitted with certain means for re-engaging the container outlet 15. The valve assembly 20 according to the present invention is believed to provide certain means for salvaging an aerosol container 11 of this sort.

As may be seen from an inspection of the various figures, the aerosol container 11 has an annular container rim as at 10 and a container outlet as at 15. The valve assembly 20 according to the present invention cooperates with both the container rim 10 and the container outlet 15 to preferably and selectively discharge container contents 13 from the container outlet 15. To achieve this primary objective, the valve assembly 20 according to the present invention preferably comprises a container-to-assembly interface fitting 28 and a plunger assembly.

The interface fitting 28 comprises a rim-receiving slot as at 40 and a through-hole as at 41. The slot 40 has a rim-receiving mouth as at 42 and is preferably defined by a C-shaped flange 43 opposed to a rim-covering lid 44. The through-hole 41 extends orthogonally from and relative to the rim-covering lid 44. The rim-receiving mouth 42 has a certain mouth width as at 102 in FIG. 24, which width 102 is slightly greater in magnitude than the diameter 101 of the container rim 10 for receiving the container rim 10. The flange 43 functions to secure the fitting 28 to the aerosol container 11 via the container rim 10, which is typically spaced from the upper portion 46 of the aerosol container 11, which spaced relationship, may thus readily receive the flange 43.

The plunger assembly essentially comprises a threaded sleeve structure 26; a specialized nut structure or plunger nut 25; and a plunger structure, which may incorporate either a plunger shaft as at 29 and a nozzle as at 23 or an integral component incorporating both a shaft and a nozzle, as exemplified by integral nozzle and shaft element 27. The sleeve structure or sleeve 26 comprises a nut-receiving cavity as at 50 and a plunger-receiving cavity as at 51.

The cavities 50 and 51 are connected or in communication with one another as generally depicted. The nut structure or nut 25 is received in the nut-receiving cavity 50 and comprises a plunger-coupling cavity as at 52, and a conduit inlet 31 communicatively engageable or otherwise cooperable with the container outlet 15 for inletting container contents 15 from the aerosol container 11 for further conveyance through the valve assembly 20.

The plunger structure or plunger shaft 29 is received in the plunger-receiving cavity 51 and the plunger-coupling cavity 52 and comprises certain plunger-based conduit as at 53 and a shaft inlet and outlet as at 54 and 55, respectively. The plunger shaft 29 is coupled to the nut 25 thereby providing matter-conducting conduit from the conduit inlet 31 to the outlet 54 via the plunger-based conduit 53.

The sleeve 26 is coupled to the through-hole 41 for enabling matter such as container contents 13 to pass from the container outlet 15 to the outlet 55 via the inlet 54 and plunger conduit 53. The valve assembly 20 according to the present invention thus functions to restore functionality to the aerosol container 11 in which the nozzle (as at 17(a) or 17(b)) is missing or in which the valve stem of the integral valve body and valve stem 18 is broken.

The valve assembly 20 may preferably comprise certain spring means as exemplified by spring 35 for biasing the plunger structure and nut 25 to a non-activated position, said spring means thus enabling the user to selectively discharge container contents. The plunger assembly of the valve assembly may further preferably comprise certain gasket means for enhancing sealed and directed delivery of container contents from the container outlet to the assembly outlet as at 30.

The plunger shaft may be preferably threadably attached to the nut 25 such that the site of threaded attachment is upstream from said gasket means thereby eliminating need for the thread sealant by closing off the thread leakage path. The plunger-receiving cavity 51 may preferably comprise certain ramped gasket seating structure as at 34 for enhancing sealed and directed delivery of container contents from the container outlet 15 to the assembly outlet 30.

As generally noted, the plunger structure of the valve assembly 20 may comprise a plunger shaft element as at 29 and at least one interchangeable nozzle, as exemplified by nozzle 23. The shaft 29 and each interchangeable nozzle 23 may be coupled to one another for enabling the user to selectively interchange one or more interchangeable nozzles 23. The interface between the shaft 29 and each interchangeable nozzle 23 may be preferably tapered, which tapered interface essentially functions to enhance the seal intermediate the shaft 29 and each interchangeable nozzle 23 and for effecting a slip resistant interface.

Further, the plunger nut 25 and the threaded sleeve 26 preferably comprise a nut-to-sleeve flat interface as at 34, which flat interface or structure 34 essentially functions to prevent the plunger nut 25 from rotating relative to the threaded sleeve 26 (and thus enabling the user to engage/disengage the plunger nut 25 with/from the plunger shaft 29 by manually rotating the plunger shaft 29 relative to the plunger nut 25.

While the above description contains much specificity, this specificity should not be construed as limitations on the scope of the invention, but rather as an exemplification of the invention. For example, it is contemplated that the present invention essentially provides an assembly for salvaging an aerosol container, which assembly comprises certain attachment means (as may be exemplified by the interface fitting) for attaching certain replacement discharge means (as may be exemplified by the plunger assembly) to an aerosol container.

It is contemplated that said attachment means may be outfitted upon an aerosol container having a compromised, damaged, or broken container outlet, and that the replacement discharge means may be attached to the aerosol container adjacent the container outlet via the attachment means so as to discharge container contents from the aerosol container via the compromised container outlet. The container contents may thus be discharged both through the container outlet and said attachment means. The discharge means may further comprise axially displaceable structure, which axially displaceable structure may well function to depress the container outlet thereby discharging container contents.

The present invention preferably thus provides a valve assembly or repair kit for salvaging a defective aerosol container, which aerosol container has an annular container rim and a container outlet. The valve assembly or repair kit comprises certain fastening means as exemplified by a container-to-assembly interface fitting as at 28 as well as a plunger assembly as previously described.

The fitting comprises a rim-receiving slot and a through-hole. The slot has a rim-receiving mouth and being defined by a flange opposed to a lid. The through-hole extends from the lid. The rim-receiving mouth has a mouth width greater in magnitude than the diameter of the container rim for receiving the container rim. The flange secures the fitting to the aerosol container via the container rim.

The plunger assembly essentially comprises a sleeve, a nut, and a plunger. The sleeve comprises nut-receiving and plunger-receiving cavities, which cavities are in communication with one another. The nut is received in the nut-receiving cavity and comprises a plunger-coupling cavity and a conduit inlet communicatively engageable with the container outlet. The plunger is received in the plunger-receiving and plunger-coupling cavities and comprises plunger-based conduit and a plunger outlet. The plunger is coupled to the nut thereby providing matter-conducting conduit from the conduit inlet to the conduit outlet. The sleeve is coupled to the through-hole for enabling matter to pass from the container outlet to the conduit outlet via the conduit inlet and plunger-based conduit.

Further, the foregoing specifications are believed to support certain methodology for discharging container contents 13 from an aerosol container 11. In this regard, the present invention is believed to support an aerosol container contents discharging method comprising the steps of: attaching a valve assembly such as assembly 20 to an aerosol can or container such as container 11 via the container rim 10 thereof, which valve assembly comprises axially displaceable conduit as comparatively depicted in FIG. 1 (in which the plunger assembly is shown in a non-activated state with the conduit being shown in a first axial position) versus FIG. 2 (in which the plunger assembly is shown in an activated state with the conduit being shown in a second axial position relative to the first axial position).

The axially displaceable conduit is thereby communicatively engageable with a container outlet 15 of the aerosol container 11. Thus, when the conduit is axially displaced towards the container outlet 15 the action is designed to release container contents 15 from the aerosol container 11 via the valve body 16, whereafter container contents are directed through said conduit to an assembly outlet as at 30 of the valve assembly 20 thereby discharging container contents 13 from the aerosol container 11.

The method may be further defined such that the step of attaching the valve assembly 20 to the container rim 10 of an aerosol can 11 may be said to comprise the step of slot-receiving the container rim 10 by the valve assembly 20. In other words, the container-to-interface fitting as at 28 slot receives the container rim 10 during the step of attaching the valve assembly 20 to the aerosol container 11, said fitting 28 thereby axially aligning the conduit 53 relative to the container outlet 15 as generally depicted in FIGS. 1-3.

As earlier set forth, at least one portion or a select portion of the valve assembly 20 is interchangeable, the interchangeability of which enables the user to, among other acts, selectively manage the conduit or assembly outlet at 30. In this regard, it is contemplated that the nozzles 23 and/or the nozzle and shaft element 27 may be interchanged for generalized maintenance and/or to alter the spray pattern as desired by the user.

As further mentioned hereinabove, the valve assembly 20 may preferably comprise certain spring means for biasing the valve assembly 20 to a non-activated position (as generally depicted in FIG. 1). In this regard, it is contemplated that the method may comprise the additional step of biasing the valve assembly conduit (as at 53) away from the container outlet 15 after directing container contents 13 through said conduit 53. The spring means thus enable the user to selectively discharge container contents 13 after attaching the valve assembly 20 to the container rim 10.

Accordingly, although the invention has been described by reference to certain preferred and alternative embodiments, and certain methodology, it is not intended that the novel disclosures herein presented be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosure, the following claims and the appended drawings. 

1. A valve assembly for restoring functionality to an aerosol container, the aerosol container having an annular container rim and a container outlet, the valve assembly comprising: a container-to-assembly interface fitting, said fitting comprising a rim-receiving slot and a through-hole, the slot having a rim-receiving mouth and being defined by a C-shaped flange opposed to a rim-covering lid, the through-hole extending from the lid, the rim-receiving mouth having a mouth width, the mouth width being greater in magnitude than the diameter of the container rim for receiving the container rim, the flange for securing the fitting to the aerosol container via the container rim; and a plunger assembly, the plunger assembly comprising a sleeve, a nut, and a plunger, the sleeve comprising nut-receiving and plunger-receiving cavities, said cavities being in communication with one another, the nut being received in the nut-receiving cavity and comprising a plunger-coupling cavity and a conduit inlet communicatively engageable with the container outlet, the plunger being received in the plunger-receiving and plunger-coupling cavities and comprising plunger conduit and an assembly outlet, the plunger being coupled to the nut thereby providing matter-conducting conduit from the conduit inlet to the assembly outlet, the sleeve being coupled to the through-hole for enabling matter to pass from the container outlet to the assembly outlet via the conduit inlet and plunger conduit, the valve assembly thusly for restoring functionality to the aerosol container.
 2. The valve assembly of claim 1 wherein the plunger assembly comprises spring means for biasing the plunger and nut to a non-activated position, said spring means thus enabling the user to selectively discharge container contents.
 3. The valve assembly of claim 1 wherein the plunger assembly comprises gasket means for enhancing sealed and directed delivery of container contents from the container outlet to the conduit outlet.
 4. The valve assembly of claim 3 wherein the plunger shaft is threadably attached to the nut, the site of threaded attachment being upstream from said gasket means thereby eliminating a thread sealant requirement.
 5. The valve assembly of claim 3 wherein the plunger-receiving cavity comprises ramped gasket seat structure, the ramped gasket seat structure for enhancing sealed and directed delivery of container contents from the container outlet to the assembly outlet.
 6. The valve assembly of claim 1 wherein the plunger comprises a shaft and at least one interchangeable nozzle, the shaft and each interchangeable nozzle being coupled to one another for enabling the user to selectively interchange one or more interchangeable nozzles.
 7. The valve assembly of claim 6 wherein the interface between the shaft and each interchangeable nozzle is tapered, the tapered interface for enhancing the seal intermediate the shaft and each interchangeable nozzle and for effecting a slip resistant interface.
 8. The valve assembly of claim 1 wherein the sleeve comprises a nut-to-sleeve flat interface, the flat interface for preventing the nut from rotating relative to the sleeve.
 9. A repair kit for salvaging an aerosol container, the aerosol container having a container rim and a container outlet, the repair kit comprising: an interface fitting, said fitting comprising fastening means for fastening the fitting to the container rim and a through-hole; and a plunger assembly, the plunger assembly comprising a sleeve, a nut, and a plunger, the sleeve comprising communicating nut-receiving and plunger-receiving cavities, the nut being received in the nut-receiving cavity and comprising a conduit inlet communicatively engageable with the container outlet, the plunger being received in the plunger-receiving cavity and comprising plunger conduit and an assembly outlet, the plunger being coupled to the nut thereby providing matter-conducting conduit from the conduit inlet to the assembly outlet, the sleeve being coupled to said fastening means for enabling matter to pass from the container outlet to the assembly outlet via the plunger assembly.
 10. The repair kit of claim 9 wherein the plunger assembly comprises spring means for biasing the plunger and nut to a non-activated position, said spring means thus enabling the user to selectively discharge container contents.
 11. The repair kit of claim 9 wherein the plunger assembly comprises gasket means for enhancing sealed and directed delivery of container contents from the container outlet to the assembly outlet.
 12. The repair kit of claim 11 wherein the plunger is threadably attached to the nut, the site of threaded attachment being upstream from said gasket means thereby eliminating a thread sealant requirement.
 13. The repair kit of claim 11 wherein the sleeve comprises a plunger-receiving cavity for receiving said plunger, said cavity comprising ramped gasket seat structure, the ramped gasket seat structure for enhancing sealed and directed delivery of container contents from the container outlet to the assembly outlet.
 14. The repair kit of claim 9 wherein the plunger comprises a shaft and at least one interchangeable nozzle, the shaft and each interchangeable nozzle being coupled to one another for enabling the user to selectively interchange one or more interchangeable nozzles.
 15. The repair kit of claim 14 wherein the interface between the shaft and each interchangeable nozzle is tapered, the tapered interface for enhancing the seal intermediate the shaft and each interchangeable nozzle and for effecting a slip resistant interface.
 16. The repair kit of claim 9 wherein the sleeve comprises a flat structure, the flat structure for preventing the nut from rotating relative to the sleeve.
 17. An assembly for salvaging an aerosol container, the assembly comprising: attachment means for attaching replacement discharge means to an aerosol container, said attachment means being attachable to an aerosol container adjacent a compromised container outlet thereof; and discharge means for discharging container contents from the aerosol container via the compromised container outlet, said discharge means being attachable to the aerosol container via said attachment means.
 18. The assembly of claim 17 wherein said discharge means discharge container contents from the aerosol container via the compromised container outlet and said attachment means.
 19. The assembly of claim 18 wherein said discharge means are axially displaceable, the axially displaceable discharge means for depressing the compromised container outlet thereby discharging container contents.
 20. A method of discharging container contents from an aerosol container, the method comprising the steps of: attaching a valve assembly to an aerosol container via the container rim thereof, the valve assembly comprising axially displaceable conduit, said conduit being communicatively engageable with a container outlet of the aerosol container; axially displacing said conduit towards the container outlet for releasing container contents from the aerosol container; and directing container contents through said conduit to an assembly outlet of the valve assembly thereby discharging container contents from the aerosol container.
 21. The method of claim 20 wherein the step of attaching the valve assembly to the container rim of an aerosol container comprises the step of slot-receiving the container rim by the valve assembly.
 22. The method of claim 21 wherein an interface fitting slot receives the container rim during the step of attaching the valve assembly to the aerosol can, said fitting thereby axially aligning the conduit relative to the container outlet.
 23. The method of claim 20 wherein a select portion of the valve assembly is interchangeable, the interchangeable select portion enabling the user to selectively manage the assembly outlet.
 24. The method of claim 20 wherein the valve assembly comprises spring means for biasing the valve assembly to a non-activated position, the method comprising the additional step of biasing the conduit away from the container outlet after directing container contents through said conduit, said spring means thus enabling the user to selectively discharge container contents after attaching the valve assembly to the container rim.
 25. A method of discharging the contents of an aerosol container in which the valve member is impaired, the method comprising a series of steps, including: radially connecting an auxiliary valve member to an aerosol container by radially moving said auxiliary valve member into attached connection with the aerosol container in adjacency to a container valve member thereby contemporaneously axially aligning the auxiliary valve member with the container valve member and additionally and contemporaneously aligning an auxiliary container discharge passageway with the container valve member: and axially moving an auxiliary plunger into contact with the container valve member to depress same and to enable container contents to be propelled through the container valve member and discharged through the auxiliary container discharge passageway in a controlled manner in accordance with the needs of the user. 